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A R T I C LE I N FO A B S T R A C T
Keywords: The solution heat treatment, forming and cold die quenching (HFQ) process has been developed and adopted for
Aluminium sheet heating forming high strength complex-shaped components of light alloys in the automotive industry. In order to exploit
Hot stamping and increase the competitiveness of this technology, production cycle time and manufacturing costs need to be
Direct flame impingement heating reduced to enable high productivity and energy efficiency. This can be realised by reducing the cycle time for
Aluminium alloy 6082
heating a metallic sheet to its solution heat treatment temperature during the HFQ process, and by decreasing
post ageing time. Rapid heating methods are capable of providing a solution to be integrated into this novel
forming technique of HFQ. This paper presents feasibility study on the adoption of the direct flame impingement
(DFI) heating method that has a high potential for non-ferrous blanks to achieve higher heating rate in HFQ
processes, compared to convection heating in a conventional furnace. The adaptability of DFI heating for HFQ
process has been validated, in terms of capability of high heating rate, quality of surface layer examination and
lap-shear strength measurement of bonded samples.
1. Introduction industry.
Existing heating methods need to be optimised in order to con-
High strength aluminium alloys, e.g. AA6082, AA6111 and AA7075, siderably reduce the heat treatment time prior to forming, which is
are suitable lightweight materials for manufacturing automobile body currently using a conventional electric or gas furnace. In addition, with
structures, which can provide a weight saving of up to 40% over steel in the development of the HFQ process, predetermined temperature pro-
most applications without compromising safety [1]. These alloys have a files in metallic blanks are required, which cannot be easily achieved
moderately high stiffness to weight ratio, good weldability, recycl- using a conventional furnace. A comparison of existing heating methods
ability, and a high level of corrosion resistance [2]. However, forming for heat treatment of blanks for sheet metal forming applications has
high strength aluminium sheets is challenging because of their rela- been carried out and presented in Section 2.
tively low formability and high springback at room temperature. Unfortunately, none of these methods are suitable for high
The solution heat treatment, forming and cold die quenching (HFQ) throughput heating of aluminium alloys in the HFQ process due to ei-
technique [3] was invented over 10 years ago and has been exclusively ther low heating efficiency or low flexibility, which results in even
industrialised by Impression Technologies Ltd. as the world-first suc- higher system costs. Direct flame impingement (DFI) heating is an al-
cessful process for forming high strength complex shaped aluminium ternative method to realise rapid heating for aluminium sheets. It
components. In a typical HFQ process, aluminium sheets are first he- provides the advantages of a rapid heating rate, high heating efficiency,
ated to a target solution heat treatment temperature at which hardening low energy consumption and high cost-effectiveness.
phase particles, i.e. precipitates, are gradually resolved into aluminium In this work, a feasibility study on the DFI heating applied, parti-
matrix during soaking. The heat treated sheets are then transferred to a cularly, for the HFQ process is performed and presented in terms of
cold die press to be simultaneously formed and quenched [4,5]. A rapid achievable high heating rates, heating rate effect on surface quality for
heating method for solution heat treatment is required to increase subsequent bonding, lap-shear strength and microstructure examina-
productivity, and further reduce turnover cycle time, energy con- tion, and a comparison with the conventional furnace heating method is
sumption and thus overall cost. This will significantly accelerate the also shown in this paper.
adoption process of this highly enabling technique for the automotive
⁎
Corresponding author.
E-mail address: jun.jiang@imperial.ac.uk (J. Jiang).
https://doi.org/10.1016/j.jmapro.2018.10.020
Received 5 May 2018; Accepted 19 October 2018
Available online 14 November 2018
1526-6125/ Crown Copyright © 2018 Published by Elsevier Ltd on behalf of The Society of Manufacturing Engineers. This is an open access article under the CC
BY-NC-ND license (http://creativecommons.org/licenses/BY-NC-ND/4.0/).
Z. Shao et al. Journal of Manufacturing Processes 36 (2018) 398–404
Convection heating in a furnace using fuel or electricity has long 3.1. Theoretical analysis of heating efficiency
heating time and low productivity. This heating method is currently
widely adopted by the automotive industry for hot steel stamping due According to the classic heat transfer theory, heat transfer formula
to its simplicity and availability. For example, 30–40 m long furnaces can be expressed as Eq. (1), where Q is heat content in Joules, m is
with an automatic conveying system are used to preheat steel blanks, mass, c is specific heat and ΔT is a change in temperature. Heat transfer
for which at least 3–4 min heating time is required for a sheet thickness rate can be presented by Newton’s law of cooling in Eq. (2), where Φ is
of 1.5–2.5 mm because of low heating efficiency [6]. The heating effi- heat transfer, A is contact area, Δt is time difference and h is convective
ciency is even lower for heating aluminium sheet, since it can take over heat transfer coefficient which can be calculated by Eq. (3). Eq. (3) is an
5 min (roughly twice as long) for the same conventional furnace to heat empirical equation proposed by Martin [15] in order to calculate the
an uncoated medium-size aluminium sheet with the thickness of 2 mm. heat transfer coefficient NuD , where r is the distance from the centre of
These types of heating furnaces must be continuously operated to avoid the workpiece, D is the diameter of the nozzle, H is the distance from
long start-up delays in practical production, which would otherwise the nozzle to the workpiece, λ and Pr are constants and Re is Reynolds
cause a drop in productivity. number calculated by Eq. (4), where ue is the velocity of the air flow
A short heating time can be realised by resistance heating, which and v is the kinematic viscosity of the air flow.
connects a sheet blank to electrodes alternatively to take current flow Q = cmΔT (1)
and to be heated by Joule’s effect, but it is feasible only for regular
shape of blanks with favourable dimensions [7] and temperature uni- Φ = hAΔt (2)
formity is exceptionally challenging for hot stamping applications [8].
hr 1 − 1.1D r
In the HFQ process, irregularly shaped aluminium sheets are usually = NuD = 2 Re0.5
D Pr
0.42 (1 + 0.005 Re0.05 )0.5
D
λ 1 + 0.1(H D − 6) D r (3)
fabricated and used for forming in order to enable a maximum draw in
of sheet materials. Mori et al. [9] studied the application of rapid re- ue D
ReD =
sistance heating for warm and hot stamping of steel sheets to reduce the ν (4)
oxidation and temperature drop during sheet transferring, but the non-
uniform temperature field in the contact area between the electrode NuD = 0.54(Gr Pr)1/4 (5)
and the sheet was observed. It has been found that this method highly By the consideration of the radiation loss in Eq. (5), the relationship of
depends on the electric resistance and the shape of the metallic sheet heating time and temperature of the workpiece can be calculated. For a
[10] even if it tends to provide an efficient heating procedure for the case study with parameters of the blank radius r of 40 mm, distance
small scale of the blank. from nozzle to the workpiece H of 30–55 mm and a nozzle diameter of
Although induction heating has been used extensively for tempering 30 mm, the effects of distance H and air flow velocity ue (in a range of
materials, it is not commonly used for heating metallic blanks because 2–8 m/s) on the heating rate are shown in Fig. 1. The flame temperature
coil design is difficult for efficient heating, particularly for heating can be estimated by using Adiabatic flame temperature calculator and
complex shaped blanks. Since induction heating [11] is a contactless fuel is methane (CH4) with an equivalence ratio of 1.0.
heating method by using induction coils to induce eddy currents in an Based on the theoretical model introduced previously, it can be seen
electrically conductive sheet within a specific distance, heating rate is that the heating rate of an aluminium blank with a diameter of 40 mm
determined by the frequency of the induced current and the material and a thickness of 1.5 mm can be almost doubled if the velocity of air
properties. The energy efficiency of induction heating is higher due to flow is raised from 2 m/s to 4 m/s, but less improvement can be ob-
less heat loss compared to convection heating in a furnace, but it has served if velocity of air flow is raised further from 4 m/s to 8 m/s. Only
low efficiency for heating non-ferrous metallic sheet with low magnetic around 10% temperature difference can be obtained at a different ve-
permeability, such as aluminium alloy, and can suffer from temperature locity of air flow when the distance from nozzle to workpiece is
uniformity issues. Infrared heating [12] has similar issues and low ef- changed from 30 mm to 55 mm.
ficiency, and it is inefficient for uncoated aluminium blanks and suffers
similar temperature uniformity issues. 3.2. Experimental programme of DFI heating
DFI heating offers an alternative method in metal forming processes
for heating blanks by hot gas or flame generated via combustion of fuel, 3.2.1. Material and specimen
which increases significantly the heating efficiency and the heat Aluminium alloy 6082 sheets of T6 temper with the thickness of
transfer rate [13], because most of non-renewable electricity sources 1.5 mm and the diameter of 180 mm (as seen in the Fig.2), which is one
(coal, natural gas, nuclear, etc.) involve burning a fuel, which converts
at best 45% of the heat produced into electricity. In a DFI furnace, a
number of high speed burning jets are usually used to obtain high heat
transfer efficiency from the combustion products to the load, and the
arrangement of jets and operating parameters, such as nozzle dimen-
sions, number of nozzles, distance between nozzles and the metal load,
fuel supply and velocity of gas flow, need to be designed and optimised
in order to realise uniform temperature distribution or predetermined
temperature profiles in blanks. However, fundamental research on DFI
[14] focuses on the investigation of combustion process, flame type and
heat transfer processes, and it has not been studied for applications to
sheet metal forming. A feasibility study is presented in the following
sections to extend the applications of DFI to HFQ forming.
Fig. 1. Heating rate at different velocities of air flow and distances from the
heating nozzle to the workpiece.
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Table 1
Chemical compositions of AA6082.
Element Si Fe Cu Mn Mg Cr Zn Ti Al
Weight 0.90 0.38 0.08 0.42 0.70 0.02 0.05 0.03 Balance Fig. 4. Effect of fuel equivalence ratio on heating rate and temperature dis-
proportion tribution (solid lines show temperature measured at the central point of the
(%) blank (T1) and dash lines show temperature measured at the distance to mid-
length of 40 mm (T2)).
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Table 2
Test matrix of conditions by DFI and thermal furnace.
Heating rate (°C/s) by Heating rate (°C/s) in Furnace
DFI
Fig. 5. The effect of gas flow rate on heating rate (solid lines show temperature
measured at the central point of the blank (T1) and dash lines show tempera-
3 20 30 3 20 30
ture measured at the distance to mid-length of 40 mm (T2)).
Soaking time (s) 1 √ √ √
30 √ √
4.1.3. Discussion
60 √ √
An array of such high-velocity flame jets impinging on a workpiece
can be designed and optimised to provide a uniform or predetermined
heating and temperature profile in a metal sheet, once the DFI heating process of 9 h at 190 °C was applied after to enable fine and well-dis-
method is integrated to HFQ. A schematic of DFI module arrangement is tributed hardening precipitates to appear in order to regain alloy’s
shown in Fig. 6, which can be used for heating up metallic blanks by strength. A test matrix of conditions by DFI and thermal furnace is
connecting DFI modules to a controllable software system. The ob- presented in Table 2. Surface layer analysis was performed under each
tained heating rate and temperature profile using DFI demonstrated testing condition.
that, compared to heating in a furnace, significantly higher heat 100 mm × 25 mm × 1.5 mm samples of AA6082 were DFI heated
transfer rate at the surface of the metal sheet and considerably lower using the same heating facility, as shown in Fig. 3, to study the changes
heat loss can be achieved using a DFI furnace. But further optimisation of surface layer after DFI heating. One pair of K-type thermocouples
of operating parameters and heating environment is required to per- was attached on the side of the sample along the width direction, and
form in future in order to achieve a higher heating rate and more connected to a data logger in order to record temperature history. In
uniform temperature distribution in the workpiece. contrast, for furnace heating, to make a better comparison of surface
layers with a similar heating rate, a target temperature of 525–545 °C
4.2. Characterisation analysis of surface layer and cross section was reached on two steel blocks. These two blocks then directly
clamped an aluminium sample to achieve a high heating rate from 20 to
4.2.1. Heat treatment of samples 36 ℃/s. It is noticed that, in this case, heating rate can only be achieved
Various HFQ testing temperature profiles of heating and cooling at 1.8 to 3 ℃/s in the absence of two hot blocks in the furnace.
processes for AA6082 are shown in Fig. 7. The aluminum sheet was
heated to the solution heat treatment temperature in a range of 4.2.2. Results of wettability tests
525–545 °C [16] at a heating rate of 1.8, 3, 30 °C/s to allow the hard- The presence of oxide layers or contaminants on the surface of an
ening precipitates to dissolve into solid solution matrix. Once the AA6082 sample can significantly reduce the subsequent bonding
temperature of the specimen reached the programmed one, various property for assembling. In order to quantify this effect, contact angle is
soaking time was selected for solution heat treatment in a range of 1 s to used to measure the wettability, an important bonding or adherence
1 min, and then water quenched to room temperature, which main- parameter, of the solid surface by a liquid [17]. In general, less than 90°
tained a supersaturated solid solution in the material. A standard ageing of contact angle is considered to be hydrophilic and larger than 90° of
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soaking time of 30 s. In summary, DFI heating will not affect the uni-
formity of grain distribution but heating in a furnace with a high
heating rate and long soaking time can result in rapid grain growth in
the material, which could affect mechanical properties of AA6082, such
as low ductility and low material strength.
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